Liquid crystal display panel, color filter and manufacturing methods thereof

ABSTRACT

A color filter and a manufacturing method thereof are provided. In the method of the invention, a substrate having a display area and a non-display area is provided. Thereafter, a black matrix is formed over the substrate, wherein black matrix defines the display area into a plurality of sub-pixel areas, and covers the non-display area, which forms an edge of the display area. Then, a color filter unit is formed in each sub-pixel area, and a light shielding layer is formed over the black matrix simultaneously. Accordingly, the shielding layer of the color filter provided by the present invention is capable of effectively reducing the light leakage from the edge of the display area.

CROSS-REFERENCE TO RELATED APPLICATION

This is a divisional application of patent application Ser. No.10/709,037, filed on Apr. 8, 2004, which claims the priority benefit ofTaiwan application serial no. 92136978, filed Dec. 26, 2003, now U.S.Pat. No. 7,335,450. The entirety of each of the above-mentioned patentapplications is hereby incorporated by reference herein and made a partof this specification.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to a color filter and themanufacturing method thereof. More particularly, the present inventionrelates to a color filter comprising a light shielding layer formed onthe black matrix of the non-display area for avoiding the light leakagefrom the edge area of the display and the manufacturing method thereof.

2. Description of the Related Art

As the development of the performance of computer, internet, andmultimedia technology, the transformation of image information hasgradually progressed from analog transformation to digitaltransformation. In recently years, the size and weight of manyelectronic device has become thin and light. As to a display device,although the conventional cathode ray tube (CRT) display is widely used,however, it has the disadvantages of large size, high radiation, heavyweight and high power consumption. Therefore, the flat panel display(FPD) is being developed having the advantages of thinner, flatter,lighter, radiation free and low power consumption, and has graduallybecome the mainstream of display devices. The flat panel display (FPD)including, for example, liquid crystal display (LCD), organic lightemitting display (OLED) or plasma display panel (PDP).

In recent year, the liquid crystal display (LCD) is developed for theapplication of full-color, larger display area, higher resolution andlow-cost. The color display of the liquid crystal display (LCD) isgenerally performed by color filters. The color filter is generallyconstructed over a transparent glass substrate, wherein a black matrixfor light shielding, and color filter units such as red filter unit,green filter unit and blue filter unit arranged corresponding to eachsub-pixel, are disposed over the transparent glass substrate. Thestructure of color filter will be described in detail hereinafter.

FIG. 1 is a cross-sectional view schematically illustrating thestructure of a conventional color filter. Referring to FIG. 1 a colorfilter 100 includes a substrate 102, black matrices 104 a and 104 b, aplurality of color filter unit 106 and a common electrode 108. Thesubstrate 102 includes a display area 102 a in the center of thesubstrate 102 and a non-display area 102 b surrounding the edge of thedisplay area 102 a. The black matrices 104 a and 104 b are disposed onthe surface of the substrate 102, wherein a plurality of sub-pixel area110 are defined by the black matrix 104 a in the display area 102 a, andthe black matrix 104 b covers the non-display area 102 b that adjacentto the edge of the display area 102 a. Furthermore, the color filterunit 106 is composed of a plurality of photoresists that have differentcolors respectively (for example, a red photoresist, a green photoresistand a blue photoresist). Each color of photoresist is disposed in thecorresponding sub-pixel area 110 defined by the black matrix 104 byperforming conventional photolithography, etching and developingprocess. Further, a common electrode 108 is further formed on thesurfaces of the black matrices 104 a, 104 b and the color filter unit106.

Next, referring to FIG. 1, a variety of color lights are generated byperforming a white light through the color filter unit 106, wherein theblack matrix 104 a of the display area 102 a is provided for separatingthe different light colors. Therefore, contrast between different lightcolors and the purity of each color are enhanced. Furthermore, the blackmatrix 104 b covering the non-display area 102 b adjacent to the edge ofthe display area 102 a is provided for preventing the leakage of lightfrom the non-display area 102 b in order to enhance the image quality ofthe liquid crystal display (LCD).

In conventional art, the material of the black matrix generally includeschromium metal. However, use of chromium metal the black matrix is anenvironmental concern, and therefore some proposed to replace thechromium metal by a black resin. It is noted that, because of the lightshielding effect provided by the black resin is poor compared to thechromium metal, a portion of lights will still leak out from thenon-display area. Thus, the light leakage from the edge of the displayarea is still a problem for the color filter.

SUMMARY OF THE INVENTION

Accordingly, to the present invention provides a color filter capable ofreducing light leakage from the edge of the display area.

The present invention also provides a method of fabricating the colorfilter mentioned above. A substrate having a display area and anon-display area formed thereon is provided. A black matrix is formedover the substrate, wherein the black matrix defines the display areainto a plurality of first sub-pixel areas, a plurality of secondsub-pixel areas and a plurality of third sub-pixel areas. The blackmatrix covers the non-display area, which forms an edge of the displayarea edge. Next, a first color filter unit is formed in each firstsub-pixel area, and a first light shielding layer is formed over theblack matrix of the non-display area simultaneously. Thereafter, atleast a second color filter unit and at least a third color filter unitis correspondingly formed in each second sub-pixel area and each thirdsub-pixel area respectively.

Furthermore, a second light shielding layer is optionally formed overthe first light shielding layer. Furthermore, a third light shieldinglayer is further optionally formed over the second light shieldinglayer. Moreover, when the color filter is provided for multi-domainvertical alignment (MVA) liquid crystal display panel, a plurality ofalignment bumps are further formed over the black matrix, the firstcolor filter unit, the second color filter unit and the third colorfilter unit.

The present invention provides a method of forming a color filter formulti-domain vertical alignment (MVA) liquid crystal display panel. Asubstrate having a display area and a non-display area formed thereon isprovided. A black matrix is formed over the substrate, wherein the blackmatrix defines the display area into a plurality of first sub-pixelareas, a plurality of second sub-pixel areas and a plurality of thirdsub-pixel areas. The black matrix covers the non-display area, whichforms an edge of the display area edge. Then, a first color filter unit,a second color filter unit and a third color filter unit arerespectively formed in the first sub-pixel areas, the second sub-pixelareas and the third sub-pixel areas. Thus, a plurality of alignmentbumps are formed over the black matrix, the first color filter unit, thesecond color filter unit and the third color filter unit. Next, a firstlight shielding layer is formed over the black matrix of the non-displayarea, which forms an edge of the display area.

Further, in the color filter described above, a second light shieldinglayer may be disposed between the black matrix and the first lightshielding layer.

Furthermore, in the color filter described above, a third lightshielding layer may be disposed between the second color filter unit andthe first light shielding layer.

Furthermore, in the color filter described above, a fourth lightshielding layer may be disposed between the third color filter unit andthe first light shielding layer.

The color filter of the present invention comprises a substrate, a blackmatrix, a plurality of color filter units and a light shielding layer.The substrate comprises a display area and a non-display area. The blackmatrix is disposed over the substrate, and the material of the blackmatrix includes, for example but not limited to, black resin. The blackmatrix defines the display area into a plurality of sub-pixel areas andcovers the non-display area that forms an edge of the display area.Furthermore, the color filter unit is disposed in the sub-pixel area,and the light shielding layer is disposed over the black matrix.

Furthermore, the color filter unit comprises, for example but notlimited to, a plurality of red photoresist units, a plurality of greenphotoresist units and a plurality of blue photoresist units. The lightshielding layer is formed together with the color filter unit.Accordingly, the light shielding layer may be comprised of a singlelayer or a multi-layer structure. The light shielding layer comprises,for example but not limited to, red photoresist, green photoresist orblue photoresist, or a combination thereof. Furthermore, the colorfilter of the present invention may also be provided for a multi-domainvertical alignment (MVA) liquid crystal display panel, wherein aplurality of alignment bumps are disposed over, for example but notlimited to, the color filter unit and the black matrix. The lightshielding layer may be formed together with the alignment bump. Further,the light shielding layer may be comprised of color photoresists or thematerial of the alignment bump.

In summary, the color filter of the present invention provides a lightshielding layer over the black matrix of the non-display area to sealthe edge of the display area. Therefore, the light leakage from the edgeof the display area can be reduced. It is to be noted that, in themanufacturing method of the color filter of the present invention, onlythe design of the mask of the color photoresist or alignment bump arerequired to be modified, however the manufacturing process and thematerials need not changed.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary, and are intended toprovide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a furtherunderstanding of the invention, and are incorporated in and constitute apart of this specification. The following drawings illustrateembodiments of the invention and, together with the description, serveto explain the principles of the invention.

FIG. 1 is a cross-sectional view schematically illustrating thestructure of a conventional color filter.

FIG. 2A to FIG. 2F are cross-sectional views schematically illustratinga process of forming a color filter according to an embodiment of thepresent invention.

FIG. 3 is a cross-sectional view schematically illustrating a structureof a color filter shown in FIG. 2.

FIG. 4 is a cross-sectional view schematically illustrating a colorfilter having double light shielding layers according to an embodimentof the present invention.

FIG. 5 is a cross-sectional view schematically illustrating a colorfilter having double light shielding layers according to anotherembodiment of the present invention.

FIG. 6 and FIG. 7 are respectively cross-sectional views schematicallyillustrating a liquid crystal display panel having a multi-domainvertical alignment (MVA) structure according to an embodiment of thepresent invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which preferred embodimentsof the invention are shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. Likenumbers refer to like elements throughout.

FIG. 2A to FIG. 2F are cross-sectional views schematically illustratinga process of forming a color filter according to an embodiment of thepresent invention. Referring to FIG. 2A, a substrate 202 is provided.The substrate includes, for example but not limited to, a transparentsubstrate comprised of a glass or a plastic material. Moreover, thesubstrate 202 is defined into a display area 202 a and a non-displayarea 202 b, wherein the non-display area 202 b surrounds the displayarea 202 a. Next, referring to FIG. 2B, a patterned black matrix layeris formed over the substrate, wherein portions of the patterned blackmatrix 204 a are formed over the display area 202 a and a portion of thepatterned black matrix 204 b is formed over the non-display area 202 b.The patterned black matrix layer comprises a non-transparent materialincluding, for example but not limited to, black resin. The patternedblack matrix can be formed by performing conventional photolithography,etching and developing process. The portions of patterned black matrix204 a defines the display area 202 a into a plurality of first sub-pixelareas 210 a, a plurality of second sub-pixel areas 210 b and a pluralityof third sub-pixel areas 210 c. The portion of patterned black matrixlayer 204 b covers the non-display area 202 b and forms an edge of thedisplay area 202 a.

Next, referring to FIG. 2C, a first color filter unit 208 a is formed inthe first sub-pixel areas 210 a. For example, a first color photoresistlayer is formed over the substrate 203 and then a conventionalphotolithography, etching and developing process may be performed overthe first color photoresist layer to form the first color filter unit208 a. At the same time, a light shielding layer 212 is formed on theportion of the patterned black matrix 204 b over the non-display area202 b.

Next, referring to FIG. 2D, a second color filter unit 208 b is formedin the second sub-pixel areas 210 b. For example, a second colorphotoresist layer is formed over the substrate 202 and then aconventional photolithography, etching and developing process may beperformed over the second color photoresist layer to form the secondcolor filter unit 208 b.

Thereafter, referring to FIG. 2E, a third color filter unit 208 c isformed in the third sub-pixel areas 210 c. For example, a third colorphotoresist is formed over the substrate 202 and then a conventionalphotolithography, etching and developing process may be performed overthe third color photoresist layer to form the third color filter unit208 c.

Finally, referring to FIG. 2F, a common electrode 214 is formed over thesubstrate 202. The common electrode 214 covers the portions of thepatterned black matrix 204 a, portion of the patterned black matrix 204b, the light shielding layer 212, the first color filter unit 208 a, thesecond color filter unit 208 b and the third color filter unit 208 c.

FIG. 3 is a cross-sectional view schematically illustrating a structureof a color filter shown in FIG. 2. Referring to FIG. 3, a liquid crystaldisplay panel 250 is formed by, for example but not limited to,performing the steps of disposing the glue 216 on the substrate,compressing the substrate and then injection the liquid crystal 218 intothe color filter 200. Accordingly, the polarization direction of thewhite light entering the thin film transistor (TFT) array substrate ischanged by the liquid crystal layer 218. Then the white light isfiltered by the first color filter unit 208 a, the second color filterunit 208 b and the third color filter unit 208 c respectively, thus avariety of color lights are generated. Because a light shielding layer212 is formed over the black matrix 204 b of the non-display area 202 b,the light shielding capability of the non-display area 202 b isimproved, and the light leakage via the edge of the display area 202 ais reduced.

In an embodiment of the present invention, a light shielding layer ofthe color filter is formed over the black matrix of the non-displayarea, which forms an edge of the display area, therefore thetransparency of the non-display area to light is also reduced. Inanother embodiment of the present invention, the light shielding layercan be formed together with any color filter unit. In an embodiment ofthe invention, for example, if the filter units of the color filter isformed using a red filter unit, a green filter unit and a blue filterunit, the light shielding layer may be formed, for example but notlimited to, together with the blue filter unit, by using a bluephotoresist layer.

FIG. 4 is a cross-sectional view schematically illustrating a colorfilter having double light shielding layers according to an embodimentof the present invention. In the invention, except for providing a colorfilter having a light shielding layer formed from the blue filter unit,a color filter having a double light shielding layer shown in FIG. 4 canalso be provided. As show in FIG. 4, a first light shielding layer 212is formed before the first color (red) filter unit 208 a is formed.Thereafter, when the second color (blue) filter unit 208 b is formed, asecond light shielding layer 212 a is formed over the first lightshielding layer 212. Thus, the light shielding layer has a double layerstructure comprising red photoresist and blue photoresist layers.

FIG. 5 is a cross-sectional view schematically illustrating a colorfilter having double light shielding layers according to anotherembodiment of the present invention. Moreover, as shown in FIG. 5, whenthe third color (green) filter unit 208 c is formed, a third lightshielding layer 212 b is formed over the second light shielding layer212 a. Thus, the light shielding layer has a triple layer structurecomprising red, blue and green photoresist layers. The light shieldinglayer is comprised of, for example but not limited to, the combinationof red, green or blue photoresist layers (for example, a combination ofred photoresist/blue photoresist or red photoresist/greenphotoresist/blue photoresist). The sequence of the photoresist in thecombination may be dependent on the manufacturing process of the colorfilter unit or the design of the mask.

In another embodiment of the present invention, the color filter and themanufacturing method of the invention can be provided for any type ofliquid crystal display panel, for example but not limited to, amulti-domain vertical alignment (MVA) liquid crystal display panel. FIG.6 is a cross-sectional view schematically illustrating a liquid crystaldisplay panel having a multi-domain vertical alignment (MVA) structureaccording to an embodiment of the present invention. The color filter300 comprises, for example but not limited to, a substrate 302, blackmatrices 304 a and 304 b, a plurality of color filter units 308, aplurality of alignment bumps 310, a light shielding layer 312 and acommon electrode 314. The substrate 302 comprises a display area 302 aand a non-display area 302 b, wherein the black matrices 304 a and 304 aare disposed-over the substrate 302. The material of the black matrices304 a and 304 a includes, for example but not limited to, a black resin.The black matrix 304 a defines a plurality of sub-pixel area 308 a inthe display area 302 a, and the black matrix 304 b covers non-displayarea 302 b, which forms the edge of the display area 302 a.

Next, referring to FIG. 6, the color filter units 308 are disposed inthe sub-pixel area 308 a respectively, and are formed, for example butnot limited to, by a variety of photoresist layers having differentcolors (such as red photoresist, green photoresist or blue photoresist)using exposing and developing process. Furthermore, the alignment bump310 is disposed over the common electrode 314 and in the display area302 a, and is formed, for example but not limited to, by performingphotolithography process including masking, exposing and developingprocess on a photosensitive material. Moreover, as shown in FIG. 6, thelight shielding layer 312 of the color filter 300 is formed with thealignment bump 310 a, and the light shielding layer 312 is disposed overthe common electrode 314 and in the non-display area 302 b adjacent tothe edge of the display area 302 a.

It is noted that, except for forming the light shielding layer describedabove with the alignment bump, a plurality of color photoresist layerscan also be formed according to the previous embodiments, as shown inFIG. 7.

Accordingly, the color filter and the manufacturing method thereof ofthe present invention can improve the problem of light leakage from theedge of the display area when the black matrix is made of black resin.It is noted that in an exemplary embodiment of the present invention,the color filter composed of blue photoresist layer has a better lightshielding effect than that of red photoresist layer, and whereas thecolor filter composed of green photoresist layer has a worse lightshielding effect. Furthermore, when the color filter is provided for amulti-domain vertical alignment (MVA) liquid crystal display panel, thelight shielding layer can be formed with the alignment bump. Moreover,if the light shielding layer is provided together with the colorphotoresist layer described above, a variety of materials may beprovided for forming the light shielding layer. Furthermore, in themanufacture of the color filter of the present invention, only thedesign of the mask is modified, but the process or and the material usedin the manufacture remain same. Therefore, the light leakage problem canbe effectively reduced and also the process is simplified.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the structure of the presentinvention without departing from the scope or spirit of the invention.In view of the foregoing, it is intended that the present inventioncover modifications and variations of this invention provided they fallwithin the scope of the following claims and their equivalents.

1. A color filter, comprising: a substrate, having a display area and anon-display area; a black matrix, disposed on the substrate, wherein theblack matrix defines the display area into a plurality of sub-pixelareas, and the black matrix covers the non-display area, which forms anedge of the display area; a plurality of color filter units, disposed inthe sub-pixel areas; a light shielding layer, disposed over the blackmatrix; and a plurality of alignment bumps, disposed over the colorfilter units and the black matrix of the non-display area adjacent to anedge of the display area, wherein the light shielding layer comprisesthe alignment bumps disposed over the black matrix on the non-displayarea adjacent to the edge of the display area.
 2. The color filter ofclaim 1, wherein the light shielding layer comprises a red photoresistlayer, a green photoresist layer and a blue photoresist layer.
 3. Thecolor filter of claim 1, wherein the alignment bumps of the color filterare provided for a multi-domain vertical alignment (MVA) liquid crystaldisplay panel.
 4. The color filter of claim 1, wherein the lightshielding layer and the alignment bumps are comprised of similarmaterial.
 5. The color filter of claim 1, wherein the black matrixcomprises a black resin.
 6. The color filter of claim 1, wherein thecolor filter units comprise a plurality of red filter units, a pluralityof green filter units and a plurality of blue filter units.
 7. A processof forming a color filter, comprising: providing a substrate having adisplay area and a non-display area; forming a black matrix over thesubstrate, wherein the black matrix defines the display area into aplurality of first sub-pixel areas, a plurality of second sub-pixelareas and a plurality of third sub-pixel areas, and the black matrixcovers the non-display area, which forms an edge of the display area;simultaneously forming a first color filter unit in each of the firstsub-pixel areas, and forming a first light shielding layer over theblack matrix; forming a second color filter unit in each of the secondsub-pixel areas; forming a third color filter unit in each of the thirdsub-pixel areas; forming a plurality of alignment bumps over the blackmatrix, the first color filter unit, the second color filter unit, andthe third color filter unit after the third color filter unit is formed;and simultaneously forming a fourth light shielding layer over the blackmatrix on the non-display area adjacent to an edge of the display areaduring the formation of the alignment bumps.
 8. The process of claim 7,further comprising: forming a second light shielding layer over thefirst light shielding layer as the second color filter unit is formed.9. The process of claim 8, further comprising: forming a third lightshielding layer over the second light shielding layer as the third colorfilter unit is formed.
 10. A liquid crystal display panel comprising: athin film transistor array substrate; a color filter, comprising: asubstrate, comprising a display area and a non-display area; a blackmatrix, disposed on the substrate, wherein the black matrix defines thedisplay area into a plurality of sub-pixel areas, and the black matrixcovers the non-display area and forms an edge of the display area; aplurality of color filter units, disposed in the sub-pixel areas; alight shielding layer, disposed over the black matrix; a plurality ofalignment bumps, disposed over the color filter units and the blackmatrix on the non-display area adjacent to an edge of the display area,wherein the light shielding layer comprises the alignment bumps disposedover the black matrix on the non-display area adjacent to the edge ofthe display area; a glue disposed between the thin film transistor arraysubstrate and the black matrix to form a sealed space therebetween; anda liquid crystal layer disposed in the space.
 11. The liquid crystaldisplay panel of claim 10, wherein the light shielding layer comprises ared photoresist layer, a green photoresist layer and a blue photoresistlayer.
 12. The liquid crystal display panel of claim 10, wherein thealignment bumps of the color filter are provided for a multi-domainvertical alignment (MVA) liquid crystal display panel.
 13. The liquidcrystal display panel of claim 10, wherein the light shielding layer andthe alignment bumps are comprised of similar material.
 14. The liquidcrystal display panel of claim 10, wherein the black matrix comprises ablack resin.
 15. The liquid crystal display panel of claim 10, whereinthe color filter units comprise a plurality of red filter units, aplurality of green filter units and a plurality of blue filter units.16. A process of forming a liquid crystal display panel, comprising:providing a substrate having a display area and a non-display area;forming a black matrix over the substrate, wherein the black matrixdefines the display area into a plurality of first sub-pixel areas, aplurality of second sub-pixel areas and a plurality of third sub-pixelareas, and the black matrix covers the non-display area, which forms anedge of the display area; simultaneously forming a first color filterunit in each of the first sub-pixel areas, and forming a first lightshielding layer over the black matrix; forming a second color filterunit in each of the second sub-pixel areas; forming a third color filterunit in each of the third sub-pixel areas; forming a plurality ofalignment bumps over the black matrix, the first color filter unit, thesecond color filter unit, and the third color filter unit after thethird color filter unit is formed; and simultaneously forming a fourthlight shielding layer over the black matrix on the non-display areaadjacent to an edge of the display area during the formation of thealignment bumps; providing a thin film transistor array substrate;disposing a glue between the thin film transistor array substrate andthe black matrix to form a sealed space therebetween; and injectingliquid crystal into the space to form a liquid crystal layer therein.17. The process of claim 16, further comprising: forming a second lightshielding layer over the first light shielding layer as the second colorfilter unit is formed.
 18. The process of claim 16, further comprising:forming a third light shielding layer over the second light shieldinglayer as the third color filter unit is formed.